Panel supporting structure



March 22, 1966 J. E. KREUZER 3,241,280

PANEL SUPPORTING STRUCTURE Filed Feb. 14, 1963 2 Sheets-Sheet 1 INVENTOR(/04 /u5 M95020? drrom/m s March 22, 1966 J. E. KREUZER PANEL SUPPORTINGSTRUCTURE 2 Sheets-Sheet 2 Filed Feb. 14, 1963 R R m 3 NU V WM 5 W M 5um w A United States Patent 3,241,280 PANEL SUPPORTING STRUCTURE JuliusE. Kreuzer, Pittsburgh, Pa., assignor to Owens- Corning FiberglasCorporation, a corporation of Dela- Ware Filed Feb. 14, 1963, Ser. No.258,437 6 Claims. (Cl. 52-311) Unsightly overhead ducts, piping andelectrical wiring may be screened by the interposition of such a panelformation, and a decorative ceiling surface may thus be substituted forthe irregular configurations derived from many present roof or permanentceiling designs.

The rectangular panels forming these sub-ceilings present a neatappearance, and generally serve for noise abatement and.control. Theyare preferably composed of fibrous glass stock which has a superiornoise reduction capacity, high thermal insulating characteristics and isvaluable in lessening fire hazards.

The panelsfor which the supporting structure of this invention isespecially intended are of a conventional type which have a densitybetween one and one half and ten pounds per cubic foot and a thicknessbetween three quarters of an inch and three inches.

Y The supporting structure for ceiling panels commonly includes anarrangement of inverted metal T-beams hung by Wires, rods or straps fromjoists or purlins with various intermediate reinforcing, members. TheT-beams may be in intersecting lattice formation in which case thepanels may be supported along all four edges upon flanges of the beams,Alternately, the beams may all run in the same direction in parallel,spaced sequence. The panels are then supported along one pair ofopposite sides only, and the unsupported side edges of the panels abutedges of adjoining panels.

Ceiling panels of fibrous glass are of limited weight and yet have amplestrength to maintain their shapes and positions in ordinary service. Dueto their inorganic nature, such panels resist warping and sagging whensubjected to water from leaks or condensation.

In view of the natural lightness and sturdiness of the panels, there isno special need of an extensive supporting system. However, variousbeams, auxiliary braces, and other members have been inserted betweenthe building elements carrying the load and the rails or beams uponwhich the panels are laid. Besides these extra members, manyinstallations also include special and intricate fastening devices tojoin the various elements together.

Such suspension systems are expensive and complicated particularly forresidential use, but are also economically objectionable in stores,business ofiices and low cost in dustrial buildings.

Fibrous glass acoustical panels as well as such panels of other lesseffective compositions have been widely sold in great quantities formany years. While basically decorative, their appearance is no longernovel and may give a plain, unexciting impression. Support means for thepanels have not been considered as contributing to an improvemet in eyeappear and are often completely concealed as considered unsightly.

It is accordingly a prime object of this invention to provide animproved panel supporting structure that is particularly attractive andis a dominating decorative feature of the ceiling assembly.

It is a further object of this invention to provide a low costsupporting structure which may be easily and quickly installed and islight in weight, but still possesses suflicient strength and rigidity tomaintain the panels in a level, orderly arrangement.

More specifically it is an object of this invention to provide a panelsupporting structure utilizing hollow supporting beams simulatingornate, sturdy wooden beams. A further object is to provide simplehollow beams of corrugated paper board imprinted with a colored, naturalwood grain effect.

A still further object is to provide such supporting structure which isparticularly suited for installation in dens, family and recreationrooms of residences, club rooms, business ofiices, and small industrialbuildings.

These and other objects and advantages of the invention are attainedprincipally through the construction and use of corrugated paper beamshaving a hollow main body portion of preferably triangular orrectangular cross section and of substantial dimensions, with anupwardly extending flat Web or tongue member by which the beam may besuspended by wires or straps from elements of the permanent ceiling orroot.

Other details and advantages of the supporting structure will bedescribed in connection with the drawings in which:

FIGURE 1 is a perspective view of a blank of corrugated paper which isscored for bending into a beam incorporating one form of this invention;

FIGURE 2 is a perspective view of an end portion of atriangularly-bodied beam shaped from the paper blank of FIGURE 1;

FIGURE 3 is a perspective, partial view of an installation of acousticalpanels utilizing beams like that shown in FIGURE 2;

FIGURE 4 is a perspective view of a modified form of triangular beamutilized as a cross beam in the installation of FIGURE 3;

FIGURE 5 shows a portion of an installation in which main beams andcross beams of rectangular cross section are the supporting members forthe panels;

FIGURE 6 is a perspective view of a frame by which the ends of the crossbeams of the installation of FIG- URE 5 are held in place;

FIGURE 7 illustrates the blank of corrugated paper from which the frameof FIGURE 6 is constructed;

FIGURE 8' shows a beam with a trapezoidal cross section; and

FIGURE 9 illustrates a beam of a semi-cylindrical cross section.

Referring to the drawings in more detail, in FIGURE 1 is shown a blank12, eight inches wide and ten to fourteen feet long of corrugated paperboard for shaping into a beam of triangular section embodying one tormof this invention, This blank is scored for bendmg longitudinally andthe blank is thus divided into sections a, a, b, b, c and c.

The side of the blank destined to be on the inner or concealed side ofthe beam structure is faced with a sheet 14 of kraft paper stockweighing forty-two pounds per thousand square feet. Next .tothis is thecorrugated kraft core or interliner 15 having a B flute corrugation, andon the opposite, or top side of the blank, as illustrated 'in FIGURE 1,is the surfacing sheet of kraft paper 18 of ninety pound weight perthousand square eet. I i s This surfacing sheet has printed on it a woodgrain design which may for instance be a reproduction of the grain ofwalnut and be of an appropriate brown color. This printing is covered bya protective coating 20 of extruded polyethylene with a thickness of0.75 of a mil. I

The three kraft components of the blank are bound together into agenerally conventional corrugated paper board by a waterproof adhesiveand given a water repellent treatment.

In FIGURE 2 is shown a portion of a beam '22 formed by bending the blank12 along the scored lines. This shaping may be accomplished by foldingthe blank around a wooden triangular form.

Through this bending the sections a and a of the blank become the twolower sides of the triangular main body 24 of the beam while sections band b form the opposite, parallel horizontal shoulders 25 which togetherconstitute the upper side of the main body.

Sections c and c extend upwardly in contiguous relation creating a web28 by which the beam is suspended. The sections and c are held securelytogether, as a seam, by a series of staples 30. In this particularembodiment the sides of the triangular body would be approximately oneand three eighths inches wide.

In FIGURE 3 is illustrated a portion of an installation of acousticalpanels 32 which are principally supported on a series of the beams 22.Each of these beams is suspended from ceiling elements by hangers whichmay be flat metal straps 34. These are inserted between sections c and cof the web 28 and are fastened thereto by bolts 36 which extend throughthe sections and through a hole in the lower end of each of the hangerstraps. The straps 34 are recommendedly spaced at four foot intervalsand may be fastened to ceiling elements such as the joist 40 by nails orscrews 42.

A flat sided beam 43, comparable in shape to half of the main beam 22when split vertically and longitudinally, is used to support the edgesof the ceiling panels abutting the walls of the rooms in which thepanels are installed. The beam lays flatly against the wall 45 and maybe fastened thereto by a staple or nail 44 extending through the upperweb portion of the beam. An upwardly facing shoulder or ledge 46 on thebeam is adapted to receive the edges of the panels 32.

Between the main beams 22 and between main beams 22 and wall beams 43 ofthe installation illustrated in FIG- URE 3 extend cross beams 48. Thesehave a main body of triangular cross section of the same dimensions asthe body of the main beams. The cross beams 48, as illustrated in FIGURE4 as well as in FIGURE 3, have an upwardly extending seam flange 50,integrated with staples 52, which projects upwardly between panels. Thecross beams are not suspended from hanger straps but instead aresupported by the attachment of their end flanges or wings 54 by staples56 to the webs 28 of the main beams 22, and the webs of the beams 43.

A complementarily shaped cut out portion 58 at the ends of the crossbeam '48 fits over the shoulder 25 and against one side of the body ofthe main beam 22 or the shoulder 46 on the side of beam 43. The crossbeams 48 are not necessarily placed vbetween all of the adjacent panelsas their function is mainly that of creating a certain architecturaleffect and accordingly they may be spaced any number of panels apart.

The acoustical panels 32 for an installation such as illustrated inFIGURE 3 may be two by four feet in the planar dimensions, and one andhalf inches thick. A panel of such thickness provide-s thermalinsulation as well as sound absorption. For decorative purposes and alsoto add some rigidity to the comparatively low density panels, a plasticfacing may be adhered somewhat tautly to the exposed surface of thepanel. This facing may, if desirable, be imprinted with a wood graindesign. A lighter color should afford an attractive contrast to the darkwalnut color of the grain imprinted upon the beams.

A beam embodying another form of this invention is presented in thefragmentary installation of FIGURE 5. This beam 62 has a main bodymember of rectangular section, a shape more closely simulating aconventional wooden ceiling beam or overhead floor joist.

A rather large size of beam such as 62 may have a body four inches wideand five inches high. As shown in FIGURE 5 the beam 62 has an upper webportion or seam 66 integrated by staples 68. Hangers 70 for suspendingthe beam are secured to the web 66 in the same manner as the hangers 34are fastened to the web 28 as explained in describing the installationshown in FIGURE 3. Acoustical panels 72 rest on the upper shoulders 64of the main beam 62.

Wooden inserts 74 fitting tightly within the body of the beam 62 andheld thereto by staples 75 maintain the beam in rectangular shape andalso provide extra strength.

The decorative cross beams 76 with rectangularly shaped bodies, in thisinstance, of smaller size than the main beams, may be mounted betweenthe main beams 62 at any desired spacing measured by one or more of thepanels 72.

The cross beam 76 has an upper web section 78 to fit between adjoiningpanels 72, and is held in position through the lodgment of its ends, inU-shaped frames 82 which may be held on the sides of main beams 62 by asuitable adhesive.

In the enlarged view of a frame 82 in FIGURE 6 it may be seen that theflat sided receiving socket portion of the frame is formed by the upperside of the lower cross member 84 and the inner faces of the uprightside arms 86. The lettering from a" through m on the sections divided byscoring of the blank 88, shown in FIGURE 7, indicates through thecorresponding lettering on the frame 82 how this element is formed byfolding the blank. Staples through or adhesive between overlyingportions of sections a and m; d and j; and e and k hold the frame in itsfolded shape.

Instead of by the frames 82 the cross beam 76 may be supported by themain beams through end wings or flanges such as the flanges 54 on crossbeams 48 shown in FIG- URES 3 and 4.

If desirable the beam of this invention may take other shapes such asthose shown in FIGURES 8 and 9. The beam of FIGURE 8 has a trapezoidalsection which would have strength comparable to the beams of FIG- URES2, 3 and 4 and might be considered to be more decorative in somecircumstances.

The arcuate lower portion of the beam 92 shown in FIGURE 9 may be, insome respects, weaker structurally than the previously described beams.However, its rounded contour is adapted to harmonize with a less angulararchitectural scheme.

From the foregoing description, in conjunction with the accompanyingdrawings, it may be seen that applicant has provided an acousticalceiling structure of a particularly novel and attractive arrangement.

The wooden beam effect has an old fashioned, mellow quality contrastingwith the rather severe nature of the usual modernistic acoustical panelinstallation.

The subject structure is particularly adapted to dens, family andrecreational rooms now most frequently wood panelled and presenting aneasy, hospitable atmosphere compared to that of formality andpreciseness quite often found in living and dining rooms.

The basic feature of the invention is considered to reside in providinglight weight, simulated wood beam supports for acoustical panels andmeans on the supports for suspending them from a permanent ceiling. Thisuniquely gives special decorative emphasis to the acoustical panelsupporting means, and creates a contoured ceiling structure quite atvariance with the usual planar acoustical panel installation.

While generally horizontal ceiling installations have been disclosed thebeams may be angled for a rafter effect.

Since light weight and low cost are most important the hollow beams ofthis invention are most desirably formed from materials such ascorrugated paper board, cardboard, or plastic sheets. The latter,particularly, could also be furnished in bright colors.

Other features of the invention include the novel structures of thecross beams, beams for setting against side walls, and supplementalattachment devices for such means.

I claim:

1. Ceiling structure including a substantially dimensioned hollow beamof folded corrugated paper, adjoining flexible edges of the corrugatedpaper forming a seam along the medial longitudinal line of the upperside of the beam, the upper side of the beam having flat horizontalareas along opposite sides of the seam, panels with border portionsresting on the flat horizontal areas of the beam and supported thereby,spaced beam hangers extending down into the seam between the adjoiningflexible edges of the corrugated paper, and means securing the hangersto the beam.

2. Ceiling structure according to claim 1 in which the outer surface ofthe hollow beam is imprinted with a wood grain design with a protectivefilm thereover of clear resin.

3. Ceiling structure according to claim 1 in which there are shaperetaining elements fitted within the beam at spaced intervalslongitudinally thereof.

4. Ceiling structure according to claim 1 in which the hollow beam isrectangular in cross section.

5. Ceiling structure according to claim 1 in which the hollow beam istriangular in cross section.

6. Ceiling structure including a substantially dimensioned hollow beamof folded flexible sheet material with its outer surface imprinted witha wood grain, adjoining flexible edges of the sheet material forming aseam along the medial longitudinal line of the upper side of the beam,the upper side of the beam having flat horizontal areas along oppositesides of the seam, panels with border portions resting on the flathorizontal areas of the beam and supported thereby, spaced beam hangersextending down into the seam between the adjoining flexible edges of thesheet material, and means securing the hangers between the flexibleedges.

References Cited by the Examiner UNITED STATES PATENTS 1,312,056 8/1919Shaw 52-86 2,150,344 3/1939 Schilling 52144 2,390,262 12/ 1945 Mazer52-506 2,816,851 12/1957 Arledter 161-413 X 2,824,342 2/ 1958 Hoyle52-726 2,990,921 7/1961 Wilde 52-495 3,013,644 12/1961 Smith 52-666FOREIGN PATENTS 1,035,353 1953 France.

123,374 1919 Great Britain.

FRANK L. ABBOTT, Primary Examiner.

JACOB L. NACKENOFF, Examiner.

J. E. MURTAGH, Assistant Examiner.

1. CEILING STRUCTURE INCLUDING A SUBSTANTIALLY DIMENSIONED HOLLOW BEAMOF FOLDED CORRUGATED PAPER, ADJOINING FLEXIBLE EDGES OF THE CORRUGATEDPAPER FORMING A SEAM ALONG THE MEDIAL LONGITUDINAL LINE OF THE UPPERSIDE OF THE BEAM, THE UPPER SIDE OF THE BEAM HAVING FLAT HORIZONTALAREAS ALONG OPPOSITE SIDES OF THE SEAM PANELS WITH BORDER PORTIONSRESTING ON THE FLAT HORIZONTAL AREAS OF THE BEAM AND SUPPORTED THEREBY,SPACED BEAM HANGERS EXTENDING DOWN INTO THE SEAM BETWEEN THE ADJOININGFLEXIBLE EDGES OF THE CORRUGATED PAPER, AND MEANS SECURING THE HANGERSTO THE BEAM.